Speed-adaptive and patient-adaptive prosthetic knee

ABSTRACT

The invention relates to an automated speed-adaptive and patient-adaptive control scheme and system for a knee prosthesis. The control scheme and system utilizes sensory information measured local to the prosthesis to automatically adjust stance and swing phase knee resistances to a particular wearer under a wide variety of locomotory activities. Advantageously, no patient-specific information needs to be pre-programmed into the prosthetic knee by a prosthetist or the patient. The system is able to adapt to various types of disturbances once the patient leaves the prosthetist&#39;s facility because it is patient-adaptive and speed-adaptive.

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/192,966, filed Mar. 29, 2000, the entire disclosureof which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to prosthetic knees in general and,in particular, to a speed-adaptive and patient-adaptive control schemeand system for an external knee prosthesis.

[0004] 2. Description of the Related Art

[0005] Most conventional active knee prostheses are variable torquebrakes where joint damping is controlled by a microprocessor as anamputee walks from step to step. Many brake technologies have beenemployed for knees including pneumatic, hydraulic andmagnetorheological.

[0006] With most current prosthetic technology, a prosthetist adjustsknee resistances to tune the artificial leg to the amputee so that theknee prosthesis moves naturally at slow, moderate and fast walkingspeeds. During use, sensors local to the prosthesis are used to detectwalking speed. A microprocessor then adjusts knee resistances based oncustomized values or data previously programmed by the prosthetist forthat specific patient only.

[0007] Disadvantageously, such a methodology for programming aprosthetic knee is time consuming for both the prosthetist and thepatient and has to be repeated for each patient. Moreover, anyunforeseen changes in the patient or in the patient's environment arenot compensated for by the knee prosthesis after the patient has leftthe prosthetist's facility. This lack of adaptiveness in the knee systemcan disrupt normal locomotion and render the pre-programmed kneeuncomfortable or even unsafe. In this situation, the patient must returnto the prosthetist's facility for the knee prosthesis to bereprogrammed. Again, undesirably this results in additional wastage oftime and further adds to the cost.

SUMMARY OF THE INVENTION

[0008] Accordingly it is one advantage of the present invention toovercome some or all of the above limitations by providing an automatedspeed-adaptive and patient-adaptive control scheme and system for a kneeprosthesis. The control scheme and system utilizes sensory informationmeasured local to the prosthesis to automatically adjust stance andswing phase knee resistances to a particular wearer under a wide varietyof locomotory activities. Advantageously, no patient-specificinformation needs to be pre-programmed into the prosthetic knee by aprosthetist or the patient. The system is able to adapt to various typesof disturbances once the patient leaves the prosthetist's facilitybecause it is patient-adaptive and speed-adaptive.

[0009] In accordance with one preferred embodiment, a method is providedof adaptively controlling the stance phase damping of a prosthetic kneeworn by a patient. The method comprises the step of providing a memoryin the prosthetic knee. The memory has stored therein correlationsbetween sensory data and stance phase damping established in clinicalinvestigations of amputees of varying body size. Instantaneous sensoryinformation is measured using sensors local to the prosthetic knee asthe patient stands, walks or runs. The instantaneous sensory informationis used in conjunction with the correlations to automatically adjuststance phase damping suitable for the patient without requiring patientspecific information to be pre-programmed in the prosthetic knee.

[0010] In accordance with another preferred embodiment, a method isprovided of adaptively controlling the swing phase damping torque of aprosthetic knee worn by a patient as the patient travels at variouslocomotory speeds. The ground contact time of a prosthetic footconnected to the prosthetic knee by a prosthetic leg is indicative ofthe locomotory speed of the patient. The method comprises the step ofcontinuously measuring the contact time over periods of one gait cycleas the patient ambulates at various locomotory speeds. The contact timeis stored within a memory of the prosthetic knee in time slotscorresponding to the locomotory speed of the patient. The swing phasedamping for knee flexion is iteratively modulated to achieve a targetpeak flexion angle range until the flexion damping converges within eachtime slot. The swing phase damping for knee extension is iterativelymodulated to control the impact force of the extending prosthetic legagainst an artificial knee cap of the prosthetic knee until theextension damping converges within each time slot. The converged dampingvalues are used to automatically control swing phase damping at alllocomotory speeds.

[0011] In accordance with one preferred embodiment, an adaptiveprosthetic knee is provided for controlling the knee damping torqueduring stance phase of an amputee. The prosthetic knee generallycomprises a controllable knee actuator, sensors and a controller. Theknee actuator provides a variable damping torque in response to commandsignals. The sensors measure the force and moment applied to theprosthetic knee as the amputee moves over a supporting surface. Thecontroller has a memory and is adapted to communicate command signals tothe knee actuator and receive input signals from the sensors. The memoryhas stored therein relationships between sensory data and stance phasedamping established in prior clinical investigations of patients ofvarying body size. The controller utilizes sensory data from the sensorsin conjunction with the relationships to adaptively and automaticallycontrol the damping torque provided by the knee actuator during stancephase independent of any prior knowledge of the size of the amputee.

[0012] For purposes of summarizing the invention, certain aspects,advantages and novel features of the invention have been describedherein above. Of course, it is to be understood that not necessarily allsuch advantages may be achieved in accordance with any particularembodiment of the invention. Thus, the invention may be embodied orcarried out in a manner that achieves or optimizes one advantage orgroup of advantages as taught herein without necessarily achieving otheradvantages as may be taught or suggested herein.

[0013] All of these embodiments are intended to be within the scope ofthe invention herein disclosed. These and other embodiments of thepresent invention will become readily apparent to those skilled in theart from the following detailed description of the preferred embodimentshaving reference to the attached figures, the invention not beinglimited to any particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Having thus summarized the general nature of the invention andits essential features and advantages, certain preferred embodiments andmodifications thereof will become apparent to those skilled in the artfrom the detailed description herein having reference to the figuresthat follow, of which:

[0015]FIG. 1 is a schematic drawing of one normal human locomotion cycleillustrating the various limb positions during stance and swing phases;

[0016]FIG. 2 is a schematic graphical representation of the variation inknee angle showing state transitions during one normal gait cycle;

[0017]FIG. 3 is a plot of biological knee angle and mechanical poweragainst percentage of a complete walking cycle for one subject;

[0018]FIG. 4 is a schematic illustration of a lower limb prostheticassembly comprising an electronically controlled prosthetic knee andhaving features and advantages in accordance with one preferredembodiment of the present invention;

[0019]FIG. 5 is a simplified block diagram representation of an adaptiveprosthetic knee system having features and advantages in accordance withone preferred embodiment of the present invention;

[0020]FIG. 6 is a diagram of one preferred embodiment of a state machinecontroller for the prosthetic knee system of FIG. 5 and showingstate-to-state transitional conditions for a gait or activity cycle;

[0021]FIG. 7 is a graph of foot contact time plotted against forwardspeed for a non-amputee moving at several steady state speeds;

[0022]FIG. 8 is a simplified schematic drawing illustrating the generaloverall configuration of one preferred embodiment of the prosthetic kneeactuator of the present invention;

[0023]FIG. 9 is a detailed exploded perspective view of amagnetorheologically actuated prosthetic knee brake having features andadvantages in accordance with one preferred embodiment of the presentinvention; and

[0024]FIG. 10 is a cross section view of the prosthetic knee of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] In order for a trans-femoral (above-knee) amputee to walk in avariety of circumstances, a prosthetic knee should provide stancecontrol to limit buckling when weight is applied to the limb. Inaddition, a prosthesis should provide swing phase control so that theknee reaches full extension just prior to heel strike in a smooth andnatural manner.

[0026] Unlike a biological knee, a prosthetic knee should accomplishboth stance and swing control without direct knowledge of its user'sintent or of the environment. Rather, a prosthetic knee has to inferwhether the amputee is walking, running, or sitting down. It should alsodetermine when subtle or drastic changes occur in the environment, suchas when the user lifts a suitcase or walks down a slope. Still further,the prosthesis should move naturally and be safe at all locomotoryspeeds, and should perform equally well for all amputees, independent ofbody weight, height, or activity level, without requiringpatient-specific information or programming from a prosthetist.

[0027] In accordance with one preferred embodiment of the presentinvention, a prosthetic knee is precisely and accurately controlled atsubstantially all locomotory speeds and for substantially all patients.The invention utilizes an adaptation scheme that automatically adjustsstance and swing resistances or damping without pre- programmedinformation from a patient or prosthetist, making the “smart” knee bothspeed-adaptive and patient-adaptive.

[0028] Normal Level-Ground Ambulation

[0029] Understanding normal human walking/running provides the basis forthe design and development of effective lower limb prostheses withcontrolled motion. Normal human locomotion or gait can be described as aseries of rhythmical alternating movements of the limbs and trunk whichresult in the forward progression of the body's center of gravity.

[0030] One typical normal level-ground gait cycle, as schematicallydepicted in FIG. 1, comprises of the activity that occurs between heelstrike of one lower limb 10 and the subsequent heel strike of the samelimb 10. The limb or leg 10 generally comprises a foot 12 and a shin orshank portion 14 coupled or articulated to a thigh portion 16 via a kneeor knee joint 18. During a single gait cycle each lower limb orextremity passes through one stance or extended phase 20 and one swingphase 22.

[0031] The stance phase 20 begins at heel-strike 24 when the heeltouches the floor or supporting ground surface and the stance kneebegins to flex slightly. This flexion allows for shock absorption uponimpact and also maintains the body's center of gravity at a moreconstant vertical level during stance.

[0032] Shortly after heel-strike 24, the sole makes contact with theground at the beginning of the foot-flat phase 26. After maximum flexionis reached in the stance knee, the joint begins to extend again, untilmaximum extension is reached at mid- stance 28 as the body weight isswung directly over the supporting extremity and continues to rotateover the foot.

[0033] As the body mass above the ankle continues to rotate forward, theheel lifts off the ground at heel-off 30. Shortly after this, the bodyis propelled forward by the forceful action of the calf-muscles (poweredplantar-flexion). The powered plantar-flexion phase terminates when theentire foot rises from the ground at toe-off 32.

[0034] During late stance, the knee of the supporting leg flexes inpreparation for the foot leaving the ground for swing. This is typicallyreferred to in the literature as “knee break”. At this time, theadjacent foot strikes the ground and the body is in “double supportmode”, that is, both the legs are supporting the body weight.

[0035] At toe-off 32, as the hip is flexed and the knee reaches acertain angle at knee break, the foot leaves the ground and the kneecontinues to flex into the swing phase. During early swing the footaccelerates. After reaching maximum flexion at mid-swing 34, the kneebegins to extend and the foot decelerates. After the knee has reachedfull extension, the foot once again is placed on the ground atheel-strike 24′ and the next walking cycle begins.

[0036] Typically, the anatomical position is the upright position,therefore flexion is a movement of a body part away from the extended orstance or anatomical position. Thus, bending of the knee is kneeflexion. Extension is a movement of a limb towards the anatomicalposition, thus knee extension is a movement in the “straightening”direction.

[0037] Stated differently, if a knee joint is looked at as a simplehinge, there are two separate actions which can occur. In “flexion”, theknee joint rotates to enable the upper and lower leg segments to movecloser together. In “extension” the knee joint rotates in the oppositedirection, the leg segments move apart and the leg straightens.

[0038] During a typical normal walking progression on a generally levelsurface, the maximum flexion angle α varies between about 60° and 80°.The maximum extension angle α_(E) is typically about or close to 180°.Thus, in level walking the normal human knee rotates through a range ofapproximately 60°-80° going from a position of fill extension in latestance to 60°-80° of flexion shortly after toe-off. In other situations,for example, in a sitting position, the maximum flexion angle α_(F) canbe about 140°-150°.

[0039] Referring to FIG. 2, preferably, the gait cycle of FIG. 1 iscategorized into five distinct states or phases. FIG. 2 schematicallyshows the knee angle θ, that is, the angle the knee rotates from fullextension, with state or phase transitions during activity that occursbetween the heel strike (HS) of one lower limb and the subsequent heelstrike (HS) of the same limb. The x-axis 36 represents time betweenconsecutive heel strikes of the walking cycle. The y-axis 38 representsthe knee angle θ.

[0040] State 1 represents early stance flexion just after heel strike(HS). State 2 represents early or mid stance extension after maximumstance flexion is reached in State 1. State 3, or knee break, typicallyoccurs at the end of stance, beginning just after the knee has fillyextended and terminates when the foot has left the ground at toe-off(TO). State 4 represents a period of knee flexion during the swing phaseof a walking or running cycle. State 5 represents a period of kneeextension during the swing phase of a walking or running cycle, aftermaximum swing flexion is reached in State 4.

[0041] As discussed later herein, these basic states or phases suggestthe framework of a prosthetic knee controller as a state machine. Thus,FIG. 2 is a graphical representation of a person moving through a normalgait cycle and the location of each state within that cycle. Table 1below summarizes the activity during each of the States 1 to 5. TABLE 1State Activity 1 Stance Flexion 2 Stance Extension 3 Knee Break 4 SwingFlexion 5 Swing Extension

[0042]FIG. 3 is a plot of typical biological knee angle and knee powerversus time normalized to the step period (adapted from Grimes, 1979).The x-axis 40 represents time normalized to the step period, T, orpercentage of walking cycle. The y-axis 42 represents knee power (P inft-lb/sec) and the y-axis 44 represents knee angle (θ in degrees).

[0043] In FIG. 3, four walking trials are shown for one subject. Zeropercent and one hundred percent mark two consecutive heel strikes of thesame leg and zero angle generally corresponds to the heel strike angle.Also, in FIG. 3, RHS represents right heel strike, RFF represents rightflat foot, LTO represents left toeoff, RHO represents right heel off.LHS represents left heel strike, LFF represents left flat foot, RTOrepresents right toe off and LHO represents left heel off.

[0044] Still referring to FIG. 3, the smaller dip 46 in the angle plot(about 15% of the full cycle) represents the flexion and extension ofthe knee during early or mid stance, whereas the larger dip 48 (about75% of the full cycle) represents the flexion and extension of the kneeduring the swing phase. Throughout the cycle, the knee mechanical poweris primarily negative or dissipative. This justifies the use oremployment of a variable damper or a variable torque brake in a kneeprosthesis. Such a variable damper or knee actuator is discussed furtherherein below.

[0045] System Configuration

[0046]FIG. 4 is a schematic illustration of a lower limb prostheticassembly or prosthesis 100 comprising an electronically controlledactive knee prosthesis 110 and having features and advantages inaccordance with one preferred embodiment of the present invention. Asdescribed in greater detail later herein, preferably, the active kneeprosthesis comprises a variable-torque braking system or damper 130 andan onboard control unit or system 120 housed in a supporting frame 141.The prosthetic knee system 110 provides resistive forces tosubstantially simulate the position and motion of a natural knee jointduring ambulation and/or other locomotory activities performed by theamputee.

[0047] At one end the artificial knee system 110 is coupled ormechanically connected to a residual limb socket 102 which receives aresidual limb, stump or femur portion 104 of the amputee. The other endof the prosthetic knee 110 is coupled or mechanically connected to apylon, shin or shank portion 106 which in turn is coupled ormechanically connected to a prosthetic or artificial foot 108.

[0048] Advantageously, the prosthetic knee system 110 of the preferredembodiments is both speed-adaptive and patient-adaptive. Thus, the kneejoint rotation is automatically controlled at substantially all speedsand for substantially all patients, regardless of body size, withoutpre-programmed information or calibrated data from a patient orprosthetist.

[0049] One main advantage of the preferred embodiments of the kneesystem is that it is able to adapt to various types of disturbances oncethe patient leaves the prosthetist's facility because it ispatient-adaptive and speed-adaptive. As an example, when the patientpicks up a suitcase, the knee responds to the disturbance automatically.With conventional technology, the patient would have to go back to theprosthetist facility to re-program their knee. In the preferredembodiments, the trial period is not typically “lengthy” and“fatiguing”.

[0050] The prosthetic knee 110 of the preferred embodimentsadvantageously permits the amputee to move and/or adapt comfortably andsafely in a wide variety of circumstances. For example, during walking,running, sitting down, or when encountering subtle or drastic changes inthe environment or ambient conditions, such as, when the user lifts asuitcase or walks down a slope.

[0051] The artificial knee 110 provides stance control to limit bucklingwhen weight is applied to the limb. In addition, the prosthetic knee 110provides aerial swing control so that the knee reaches full extensionjust prior to or at heel-strike in a smooth and natural manner.

[0052] Preferably, the artificial knee system 110 of the presentinvention is used in conjunction with a trans-femoral (above-knee, A/N)amputee. Alternatively or optionally, the prosthetic knee 110 may beadapted for use with a knee-disarticulation (K/D) amputee where theamputation is through the knee joint, as needed or desired, giving dueconsideration to the goals of achieving one or more of the benefits andadvantages as taught or suggested herein.

[0053] Knee Electronics

[0054]FIG. 5 illustrates one preferred embodiment of the prosthetic kneesystem 110 of the invention in block diagram format. In FIG. 5, thesolid communication lines represent signal/data flow and the phantom ordashed communication lines represent energy flow.

[0055] As stated above, preferably, the automated prosthetic knee system110 generally comprises a variable-torque braking system or damper 130and an onboard control unit or system 120. The feedback control system120 comprises a central controller 132 which receives sensory anddiagnostic information to control the operation of the knee actuator 130and other associated equipment (as discussed below). For purposes ofclarity, the various components of the prosthetic knee system 110, inaccordance with one preferred embodiment, are listed in Table 2 below.TABLE 2 Component(s) Reference Numeral Knee Actuator 130 Microprocessor132 Knee Angle Sensor 134 Knee Angle Amplifier 136 Knee AngleDifferentiator 138 Axial Force and Moment Sensors 140 Axial Force andMoment Amplifiers 142 Battery Monitoring Circuit 144 Moisture DetectionCircuit 146 Power Usage Monitoring Circuit 148 Memory 150 SerialCommunications Port 152 Safety Mechanism 154 Safety Mechanism Driver 156Safety Watchdog Circuit 158 Knee Actuator Current Amplifier 160 AudibleWarning Transducer 162 Audible Warning Circuit 164 Vibration Transducer166 Vibration Warning Generator 168 Battery 170 Battery ProtectionCircuitry 172 Battery Charge Circuit 174 Circuit Power Supplies 176Circuit Power Conditioners 178

[0056] As mentioned above, the knee actuator 130 comprises a variabletorque brake or damper for modulating joint damping to control extensionand flexion movements based on command signals from the knee controller132. The manner in which the control scheme of the preferred embodimentscontrols knee joint rotation is discussed in further detail laterherein.

[0057] The knee actuator or brake 130 can comprise any one of a numberof conventional brakes. These include without limitation (i) dryfriction brakes where one material surface rubs against another surfacewith variable force; (ii) viscous torque brakes using hydraulic fluidsqueezed through a variable sized orifice or flow restriction plate; and(iii) magnetorheological (MR) brakes or dampers where MR fluid(containing small iron particles suspended in the fluid) is squeezedthrough a fixed orifice or flow restriction plate, with viscosity of thefluid being varied in response to an applied magnetic field. Optionally,the knee brake 130 comprises a pneumatic brake, as known in the art.

[0058] In one preferred embodiment, and as discussed in further detaillater herein, the knee brake 130 comprises a variable torque rotarymagnetorheological (MR) brake that operates in the shear mode. MR fluidis sheared between a plurality of rotors and stators to generate avariable and controlled damping effect which precisely and accuratelymodulates the knee joint rotation.

[0059] In one preferred embodiment, the prosthetic knee system 110comprises an artificial knee cap or extension stop to limit the maximumknee extension. The artificial or prosthetic knee cap is preferablybelow the knee actuator 130 and is mechanically connected to the kneeactuator 130 and/or the frame 141.

[0060] The knee actuator current amplifier 160 comprises a circuit whichgenerates the needed or desired current from the battery 170 in the kneeactuator 130 to modulate the damping torque provided by the knee brake130. Command signals or instructions from the microprocessor 132 to theknee actuator current amplifier 160 determine the current supplied tothe knee actuator 130, and hence the amount of damping torque generated.

[0061] The onboard microprocessor 132 including memory 150 are local tothe prosthetic knee system 110. The microprocessor 132 is the primarycomputational unit of the prosthetic knee system 110 and receives inputelectrical signals from the various components of the knee system 110,processes them, and generates output electrical signals to monitor andcontrol the actuations of the prosthetic knee 130 and other associatedcomponents, as necessary.

[0062] The microprocessor 132 includes circuitry which digitizesincoming signals and generates outgoing analog signals. Themicroprocessor further includes timing modules and watchdogself-resetting circuitry. The memory 150 comprises internal or externalvolatile and non-volatile memory.

[0063] The microprocessor 132 preferably comprises a Motorola 68HC12B3216 bit series microprocessor. This processor has 8 channel analog todigital conversion capability, 32K of flash and 768 bytes of EEPrommemory. The external memory comprises two industry standard 32K by 8 bitstatic RAMs. The serial flash is an Atmel AT45D081 and uses the serialcommunications interface (SCI) provided by the microprocessor.

[0064] The serial communications port 152 provides an interface betweenthe knee electronics, via the microprocessor 132, and externaldiagnostic, data logging and programming equipment. The port 152 canefficaciously comprise any one of a number of commercially availablecommunication ports, for example, RS232, RS485, ethernet and the like,as needed or desired, giving due consideration to the goals of achievingone or more of the benefits and advantages as taught or suggestedherein.

[0065] The microprocessor 132 along with the other associated sensory,diagnostic safety and protection circuitry of the prosthetic knee system110 are preferably mounted on a circuit board to provide a compactassembly. The circuit board is preferably housed within and secured tothe frame 141 directly or utilizing an intermediate shell or cover toprotect the circuit board and components mounted thereon.

[0066] The knee angle sensor 134 is used to encode the absolute kneeangle. Preferably, the knee angle sensor 134 measures the degree towhich a single degree-of-freedom knee joint is flexed or extended. Theknee angle amplifier 136 comprises a circuit which conditions the signalreceived from the knee angle sensor 134 and feeds it to themicroprocessor 132 for knee control purposes, as discussed below.

[0067] The knee angle differentiator 138 comprises a circuit whichdifferentiates the signal received from the knee angle sensor 134 todetermine the rotational or angular velocity of the knee and feeds thissignal to the microprocessor 132 for knee control purposes, as discussedbelow. The knee angular velocity signal further determines whether theknee is flexing or extending.

[0068] The angle sensor 134 is preferably mounted on the frame 141 (FIG.4). Alternatively, the angle sensor 134 is mounted on the side of theknee actuator 130 or directly below the knee actuator 130, as needed ordesired.

[0069] In one preferred embodiment, the angle sensor 134 comprises anangle sensing potentiometer. In another preferred embodiment, the anglesensor 134 comprises an optical shaft encoder. In yet another preferredembodiment, the angle sensor 134 comprises a magnetic shaft encoder. Inother preferred embodiments, alternate knee angle sensing devices may beutilized with efficacy, as required or desired, giving due considerationto the goals of accurately estimating the knee angle, and/or ofachieving one or more of the benefits and advantages as taught orsuggested herein.

[0070] The axial force and moment sensors 140 comprise a transducer thatgenerates signals proportional to the lower leg axial force and momentor torque. In one preferred embodiment, the transducer comprises a forestrain gage sensor and an aft strain gage sensor. To compute axialforce, the fore and aft signals are added, and to compute the moment,the signals are subtracted. The axial force and moment amplifiers 142condition the signals received from the axial force and moment sensors140 and feed it to the microprocessor 132 for knee control purposes, asdiscussed below.

[0071] The axial force sensors 140 measure the component of forceapplied to the knee prosthesis 110 from the ground or other supportingsurface in a direction substantially along or parallel to the shinlongitudinal axis 180 (FIG. 4) or knee long axis. The axial forcemeasurement is used to determine whether the prosthetic foot 108 (FIG.4) is on or off the ground or other supporting surface. That is, a zeroaxial force indicates that the foot 108 is not on the ground, forexample, in the swing phase, while a non-zero axial force indicates thatthe foot 108 is on the ground, for example, in the stance phase.

[0072] The torque or moment sensors 140 measure the component of torqueapplied to the knee prosthesis 110 in a medial-lateral direction 182 asshown in FIG. 4. In addition, the moment sensors 140 determine whetherthe applied knee moment is a flexion or extension moment. Typically, atheel strike a flexion moment is applied to the knee prosthesis 110,tending to flex the knee joint, and throughout late stance an extensionmoment is applied, tending to extend the joint.

[0073] The axial force and moment sensors 140 are preferably mounted onthe frame 141 (FIG. 4). In one preferred embodiment, the axial force andmoment sensors 140 comprises a strain gauge load cell. In anotherpreferred embodiment, the axial force and moment sensors 140 comprise adeflection encoded shock/spring mechanism. In other preferredembodiments alternate load and/or moment sensing devices may be utilizedwith efficacy, as required or desired, giving due consideration to thegoals of accurately estimating the axial load and/or applied moment,and/or of achieving one or more of the benefits and advantages as taughtor suggested herein.

[0074] In one preferred embodiment, the axial force and moment sensors140 comprise a plurality of strain gauges. Preferably, four gauges areused with two strain gauges mounted on the front 184 of the frame 141and two strain gauges mounted on the rear 186 of the frame 141 tomeasure and differentiate between load on the heel of the foot 108 andload on the toe of the foot 108. Stated otherwise, the strainmeasurement provides an indication as to whether the center of gravityis in an anterior, centered or posterior position relative to theprosthetic foot 108.

[0075] The strain gauges are preferably arranged in a wheatstone bridgeconfiguration to generate an electric signal which changesproportionally with bending moment strain. As the skilled artisan willrecognize, such a wheatstone bridge configuration is a standardarrangement for determining the resistance change of strain gauges.

[0076] The battery monitoring circuit 144 continuously or periodicallymonitors the battery voltage, current and temperature for safetypurposes. The data from the battery monitoring circuit 144 iscontinuously or periodically provided to the microprocessor 132 tofacilitate in constraining the knee operation to within the batterymanufacturer's specification.

[0077] The moisture detection circuit 146 continuously or periodicallymonitors the moisture levels for safety purposes and senses any abnormalmoisture on the system circuit board and/or other associated systemcircuitry due to condensation, submersion and the like. The data fromthe moisture detection circuit 146 is continuously or periodicallyprovided to the microprocessor 132.

[0078] In one preferred embodiment, the moisture detection circuit 146comprises interdigitated copper traces. In other preferred embodiments,the moisture detection circuit can comprise alternate moisture detectingdevices with efficacy, as required or desired, giving due considerationto the goals of reliably detecting moisture levels on the systemelectronics, and/or of achieving one or more of the benefits andadvantages as taught or suggested herein.

[0079] The power usage monitoring circuit 148 continuously orperiodically measures the power consumption by the knee actuator 130 forsafety purposes. The data from the power usage monitoring circuit 148 iscontinuously or periodically provided to the microprocessor. Inaddition, the power usage monitoring circuit 148 or other independentcircuits may be utilized, as needed or desired, to measure the powerconsumption by other electronic components of the prosthetic knee system110.

[0080] The prosthetic knee system 110 preferably comprises a safetysystem including the safety mechanism 154. The safety mechanism 154 isactuated or activated to put the system 110 in a default safety modewhen a system error is detected by the microprocessor 132. Such a systemerror can occur if abnormal behavior is noted in any of the signals fromthe knee angle sensors 134, the axial force and moment sensors 140, thebattery monitoring circuit 144, the moisture detection circuit 146 andthe power usage monitoring circuit 148 indicating a system malfunctionand/or other concern over the integrity of the knee actuator 130.

[0081] Detection of a system error causes the safety mechanism oractuator 154 to activate a safety default mode such that even with asystem malfunction the prosthetic knee system 110 remains safe for theamputee. For example, in the safety default mode, the knee could resistflexion but could be free to extend, thereby ensuring the safety of thepatient.

[0082] The safety mechanism driver 156 comprises a power amplifier thatturns on or off the safety default mode of the safety mechanism 154based on command signals or instructions from the microprocessor 132.The safety watchdog circuit 158 comprises a circuit which isperiodically or continuously “attended” to by signals from themicroprocessor 132 to prevent the watchdog circuit 158 fromunnecessarily enabling the safety default mode by sending signals to thesafety mechanism driver 156. In other words, the safety watchdog circuit158 would activate the safety mechanism 154 unless otherwiseperiodically or continuously instructed so by the microprocessor.

[0083] Preferably, and when possible, to warn the user of a systemmalfunction or unusual operating condition, prior to the activation ofthe default safety mode, either one or both of the audible warningtransducer 162 and the vibration transducer 166 are activated. Theaudible warning circuit 164 comprises an amplifier which generates anelectronic signal to create audible noise by the warning transducer 162when enabled. The audible warning circuit 164 receives command signalsor instructions from the microprocessor 132.

[0084] The audible warning transducer 162 is preferably housed in orsecured to the frame 141 (FIG. 4). In one preferred embodiment, theaudible warning transducer 162 comprises a piezo speaker. In otherpreferred embodiments, alternate sound generating devices may beutilized with efficacy, as required or desired, giving due considerationto the goals of warning the user, and/or of achieving one or more of thebenefits and advantages as taught or suggested herein.

[0085] The vibration transducer 166 comprises an actuator which vibratesthe prosthetic knee system 110 in such a way as to draw attention fromthe wearer. The vibration warning generator 168 comprises an amplifierwhich generates an electronic signal to turn on the vibration transducer164 when enabled. The vibration warning generator 168 receives commandsignals or instructions from the microprocessor 132.

[0086] The vibration transducer 166 is preferably mounted on the systemcircuit board. Alternatively, the vibration transducer 166 is housed inor secured to the frame 141 (FIG. 4). In one preferred embodiment, thevibration transducer 166 comprises a wobble motor. In other preferredembodiments, alternate vibration generating devices may be utilized withefficacy, as required or desired, giving due consideration to the goalsof warning the user, and/or of achieving one or more of the benefits andadvantages as taught or suggested herein.

[0087] The onboard battery or power source 170 supplies power to theknee actuator 130, the safety mechanism 154, the audible warningtransducer 162 and the vibration transducer 166. The circuit powerconditioners 178 convert the raw battery power to power that isconditioned for use by the microprocessor 132 and other sensorycircuitry and individual system subcircuits. The circuit power supplies176 provide the conditioned power to the microprocessor 132 and othersensory circuitry and individual system subcircuits.

[0088] Thus, via the circuit power supplies 176 and the circuit powerconditioners 178, the battery 170 distributes power to themicroprocessor 132 and other sensory circuitry and individual systemsubcircuits including the knee angle amplifier 136, the knee angledifferentiator 138, the axial force and moment amplifiers 142, thebattery monitoring circuit 144, the moisture detection circuit 146, thepower usage monitoring circuit 148, the safety watchdog circuit 158, thesafety mechanism driver 156, the knee actuator current amplifier 160,the audible warning circuit 164, the vibrator warning generator 168 andany other associated circuits, as necessary.

[0089] The battery protection circuitry 172 protects the battery 170from exceeding safe operating conditions. If desired, a battery state ofcharge indicator may also be provided. The battery charge circuitry 174converts power from a charging source, typically a wall outlet, to thepower levels suited for the battery 170.

[0090] The Control Scheme

[0091] The State Machine

[0092] The basic phases or states of biological gait (as discussedabove) suggest the framework of the prosthetic knee controller as astate machine. Thus, each phase corresponds to a State 1 to 5 (see, forexample, FIG. 2 and Table 1). FIG. 6 is a diagram of one preferredembodiment of a state machine controller 190 of the prosthetic kneesystem 110 and shows state-to-state transitional conditions.

[0093] As discussed above, the onboard knee angle sensor 134 measuresthe knee angle and the onboard axial force and moment sensors 140measure the axial force and the knee moment. The knee angle data, theknee rotational velocity data, the axial force data and the knee momentdata are provided to the microprocessor or main controller 132 todetermine system state, and accordingly automatically control theactuations of the knee brake or actuator 130 to modulate knee jointrotation.

[0094] Also as discussed above, the knee angle signal determines thedegree of knee joint rotation and the knee angular velocity signaldetermines whether the knee is flexing or extending. The axial forcemeasurement determines whether the prosthetic foot is on or off theground or other supporting surface. The knee moment measurementdetermines whether the applied knee moment is a flexion or extensionmoment.

[0095] Based upon these sensory data provided to the microprocessor 132,the state machine controller 190 cycles through the various States 1, 2,3, 4 and 5 as the user moves through each gait cycle or other locomotoryactivity. Often, and as seen in FIG. 6, the controller 190 changes statedepending on whether the moment is above or below an extension momentthreshold or critical value. Advantageously, and as discussed below,these threshold moments are automatically self-learned or self-taught bythe prosthetic knee system of the preferred embodiments for eachindividual patient without pre-programmed information about the specificpatient.

[0096] Preferably, the control of the state machine 190 on the behaviorof the knee damper 130 allows the patient to perform a wide variety ofactivities. These include normal walking or running on a level orinclined surface, sitting down, ascending or descending steps or othersituations, for example, when a user lifts a suitcase. Again, in theseand other situations, the prosthetic knee system of the preferredembodiments automatically provides for accurate knee damping controlwithout pre-programmed information about the specific patient.

[0097] The overall operation of the state machine controller 190 and thevarious conditions that are satisfied between state-to-state transitionsare now described in accordance with one preferred embodiment. Based onthe input sensory data (as described above) these provide information tothe knee brake 130 on how to modulate knee damping. The control actionsfor each state are described later herein.

[0098] First, the state transitions and conditions for these transitionsare described for a typical walking or running cycle. As stated above,the axial force is the component of force applied to the knee prosthesis110 from the ground or other supporting surface in a directionsubstantially along or parallel to the shin longitudinal axis 180 (FIG.4) or knee long axis. The applied moment is the component of torqueapplied to the knee prosthesis 110 in a medial-lateral direction 182 asshown in FIG. 4.

[0099] State 1 (stance flexion) transitions to State 2 (stanceextension) under condition C12. Condition C12 is satisfied when the kneefirst achieves a small extension velocity. At this stage, the prostheticfoot is on the ground or other supporting surface.

[0100] State 2 (stance extension) transitions to State 3 (knee break)under conditions C23. Conditions C23 are satisfied when the extensionmoment is below a threshold or critical level or value, when the knee isat or close to full extension, and when the knee has been still for acertain amount of time.

[0101] State 3 (knee break) transitions to State 4 (swing flexion) undercondition C34. Conditions C34 is satisfied when the axial force fallsbelow a threshold or critical level or value. That is, at this stage theprosthetic foot is off or nearly off the ground or other supportingsurface.

[0102] State 4 (swing flexion) transitions to State 5 (swing extension)under condition C45. Condition C45 is satisfied when the knee firstbegins to extend. At this stage, the prosthetic foot is still off theground or other supporting surface.

[0103] State 5 (swing extension) transitions back to State 1 (stanceflexion) under condition C51. Condition C51 is satisfied when the axialforce climbs above a threshold or critical level or value. Thiscompletes one walking or running gait cycle.

[0104] As indicated above, the state-to-state transitions may followother patterns than the State 1 to State 2 to State 3 to State 4 toState 5 scheme depending on the particular activity of the amputeeand/or the ambient or terrain conditions. Advantageously, the finitestate machine controller 190 automatically adapts to or accommodates forsituations in which alternate state transitions may occur to provide theamputee with options of achieving a wide variety of substantiallylife-like or natural movements under diverse external conditions.

[0105] State 1 (stance flexion) transitions to State 3 (knee break)under conditions C13. Conditions C1 3 are satisfied when the extensionmoment is below a threshold or critical level or value, when the knee isat or close to full extension, and when the knee has been still for acertain amount of time. This state transition from State 1 to State 3can occur when the amputee fails to go through the normalflexion-extension cycle during stance.

[0106] State 1 (stance flexion) transitions to State 4 (swing flexion)under condition C14. Condition C14 is satisfied when the axial forcefalls below a small but nonzero threshold or critical level or value.This state transition from State 1 to State 4 can occur when the amputeestands on the knee but alternately shifts back and forth, weighting andunweighting the prosthesis.

[0107] State 2 (stance extension) transitions to State 1 (stanceflexion) under condition C21. Condition C21 is satisfied when the kneeachieves a small but nonzero flexion velocity. This state transitionfrom State 2 to State 1 can occur if the amputee begins to flex the kneeduring the extension period of stance.

[0108] State 2 (stance extension) transitions to State 4 (swing flexion)under condition C24. Condition C14 is satisfied when the axial forcefalls below a threshold or critical level or value. This statetransition from State 2 to State 4 can occur if the amputee lifts hisfoot during the extension period of stance.

[0109] State 3 (knee break) transitions to State 1 (stance flexion)under conditions C31. Conditions C31 are satisfied when the knee hasbeen in State 3 for a certain amount of time, OR if the extension momentis above a threshold or critical level AND when the knee is at fullextension or close to full extension. This state transition from State 3to State 1 can occur if the amputee leans back on his heels from astanding position.

[0110] State 4 (swing flexion) transitions to State 1 (stance flexion)under condition C41. Condition C41 is satisfied when the axial forceclimbs above a small but nonzero threshold or critical value. This statetransition from State 4 to State 1 can occur if the amputee stands onthe knee but alternately shifts back and forth, weighting andunweighting his prosthesis.

[0111] As discussed above, based upon input sensory data, the controller190 cycles through the states as the user moves through each gait cycleor activity. The state machine software is resident within themicroprocessor 132 or memory 150. Next, the various control actions orscheme for each state are described. The control scheme for States 1, 2and 3 is referred to as “stance phase control” and the control schemefor States 4 and 5 is referred to as “swing phase control.”

[0112] Stance Phase Control

[0113] In accordance with one preferred embodiment, a scheme is providedto adaptively control the stance phase damping of a prosthetic knee wornby a patient. Stored in the memory of the prosthetic knee arecorrelations relating sensory data and stance phase damping. Establishedin clinical investigations of amputees of varying body size theserelations characterize knee behavior when the prosthetic foot is incontact with the ground. Sensory information are used in conjunctionwith these correlations to define how stance phase damping should bemodulated in standing, walking and running.

[0114] In accordance with one preferred embodiment, an adaptiveprosthetic knee is provided for controlling the knee damping torqueduring stance phase of an amputee. The prosthetic knee generallycomprises a controllable knee brake, sensors and a controller. The kneebrake provides a variable damping torque in response to command signals.The sensors measure knee angle, axial force and applied moment as theamputee moves over a supporting surface. The controller has a memory andis adapted to communicate command signals to the knee brake and receiveinput signals from the sensors. The memory has stored thereinrelationships between sensory data and stance phase damping establishedin prior clinical investigations of patients of varying body size. Inaddition, biomechanical information is stored in memory to guide themodulation of damping profiles. The controller utilizes sensory datafrom the sensors in conjunction with both clinical and biomechanicalinformation to adaptively and automatically control the damping torqueprovided by the knee brake during stance phase independent of any priorknowledge of patient size.

[0115] State 1 (Stance Flexion) and State 2 (Stance Extension):

[0116] In normal gait, the knee first flexes and then extends throughoutearly to midstance (see FIGS. 2 and 3). In State 1, or stance flexion, aprosthetic knee should preferably exert a resistive torque or damping toinhibit the knee from buckling under the user's weight. A prostheticknee should also preferably exert a resistive torque or damping duringthe extension period of stance, or State 2, to slow or damp kneeextension so that the knee does not overextend, thereby preventing therotating portion of a knee, such as the knee brake, to slam against aprosthetic kneecap (extension stop) or outer knee cover.

[0117] The degree to which a prosthetic knee should dampen flexion andextension so as to closely simulate a life-like or natural response islargely dependent on body weight. That is, in States 1 and 2 largerdamping values are preferred for larger users so as to more faithfullysimulate a generally life-like or natural feel. (Note that in general atall user does require a greater knee resistance but tall peopletypically tend to rotate the knee faster thereby increasing the torqueresponse of the system—current is proportional to knee rotationalvelocity where the proportionality constant is knee damping.)

[0118] In accordance with one preferred embodiment, clinical studieswere performed with amputees of different body sizes ranging fromsmall/light to large/heavy to generally capture the full range of bodysizes. These users utilized prosthetic knees and other sensoryequipment. Preferably, the users utilized the prosthetic knee brake 130along with the axial and moment sensors 140 and the knee angle sensor134.

[0119] In these clinical investigations, flexion and extension dampingvalues provided by the knee actuator 130 were optimized for amputees ofdifferent body size while monitoring the axial force, knee moment, kneeangle and knee angular velocity data, among other associated data, asnecessary. These data were then used to establish relationships orcorrelations between stance phase resistances and sensory informationmeasured and/or computed during stance.

[0120] Preferably, the clinical study data is collected over a widevariety of patient activities and/or external conditions and terrain.These include normal walking or running on a level or inclined surface,sitting down, ascending or descending steps or other situations, forexample, when a user lifts a suitcase, among other.

[0121] The optimized stance phase knee resistance or damping and sensorydata relationships or correlations for patients of varying body size arestored or programmed in the controller or microprocessor 132 or systemmemory 150. These are used in the prosthetic knee system 110 of thepreferred embodiments to automatically control the actuations of theknee brake 130.

[0122] When an amputee first walks utilizing the prosthetic knee system110 as controlled by the preferred control schemes of the invention,preferably, the microprocessor or controller 132 initially sets State 1damping or resistance to knee rotation to a large value. For a lineardamper in which torque is proportional to knee rotational velocity, anadequate proportionality constant, or damping value, is 20 Nm*secondsper radian. This ensures that the prosthetic knee 110 is safe and doesnot buckle to exceedingly large flexion angles. Preferably, this maximumflexion angle does not exceed 15°.

[0123] In distinction to initial State 1 damping, preferably, themicroprocessor or controller 132 initially sets State 2 damping orresistance to knee rotation to a smaller value. For a linear damper inwhich torque is proportional to knee rotational velocity, an adequateproportionality constant, or damping value, is 10 Nm*seconds per radian.This allows the amputee to extend the knee even if the knee happens tobecome flexed.

[0124] As the amputee starts moving and taking several steps, the axialforce and moment sensors 140 and the angle sensor 134 are continuouslyor periodically providing axial force, applied moment, knee angle andknee angular velocity data or signals to the microprocessor orcontroller 132. These sensory data, and in particular the peak force andpeak torque and/or the axial force and torque profiles applied to theprosthetic knee system 110, are used by the controller 132 to adjust theflexion and extension damping to values or profiles that were determinedto give reasonable or optimized or generally life-like stance behaviorduring the prior clinical investigations.

[0125] As discussed above, the relationships or correlations obtainedduring these clinical investigations of a wide range of patients havingvarying body sizes have been programmed or stored in the controller 132.As the patient continues to use the prosthetic knee system 110, furtherautomated refinements and fine-tuning can be made by the system 110, asnecessary.

[0126] The prosthesis of the preferred embodiments is a self-teachingand/or self- learning system that is guided by clinical (prosthetic) andbiomechanical knowledge. For example, biomechanical knowledge (stored inthe system memory) includes information related to the mechanics oftypical human walking/running, as discussed above in reference to FIG.1.

[0127] Moreover, the clinical relationships or correlations also allowthe prosthetic knee system 110 to determine the appropriate “thresholdmoments” for the particular amputee independent of body size. Asdiscussed above, these threshold moments are used by the state machine190 (FIG. 6) to change state depending on whether the threshold momentis above or below certain values specific to the patient.

[0128] Advantageously, in the preferred embodiments, no patient-specificinformation needs to be pre-programmed into the prosthetic knee by aprosthetist or the patient. Using sensory information measured local tothe knee prosthesis, stance resistances automatically adapt to the needsof the amputee, thereby providing an automated patient-adaptive system.

[0129] State 3 (Knee Break):

[0130] In one preferred embodiment, State 3 (knee break) knee damping orresistance is maintained substantially constant and minimized so thatthe amputee can easily flex the knee. Preferably, this minimum value ofthe knee damping torque is about 0.4 N-m and is largely determined bythe particular knee brake utilized. Alternatively, other minimum dampingtorque values and/or variable torques may be utilized with efficacy, asneeded or desired, giving due consideration to the goals of achievingone or more of the benefits and advantages as taught or suggestedherein.

[0131] In another preferred embodiment, the State 3 knee damping ortorque is determined as described above for States 1 and 2. That is,measured sensory data, and in particular the peak force and peak torqueand/or the axial force and torque profiles applied to the prostheticknee system 110, are used by the controller 132 to adjust the kneeresistance or damping to values or profiles that were determined to givereasonable or optimized or generally life-like stance behavior duringprior clinical investigations.

[0132] Swing Phase Control

[0133] In accordance with one preferred embodiment, a scheme is providedof adaptively controlling the swing phase damping torque of a prostheticknee worn by a patient as the patient travels at various locomotoryspeeds. The ground contact time of a prosthetic foot, measured from heelstrike to toe-off, has been shown to correlate well with forwardlocomotory speed. The scheme comprises the step of continuouslymeasuring foot contact time as an estimate of the patient's forwardspeed, and adaptively modulating swing phase damping profiles until theknee is comfortable and moves naturally. The swing phase damping profilefor knee flexion is iteratively modulated to achieve a particular rangeof peak flexion angle. In distinction, for knee extension, knee dampingis modulated to control the impact force of the extending leg againstthe artificial knee cap. The converged damping values are used toautomatically control swing phase damping at all locomotory speeds.

[0134] In one preferred embodiment, during stance phase the controller132 computes a parameter, based on input sensory data, that changes withlocomotory speed of the amputee. Preferably, this parameter changesmonotonically with locomotory speed. As discussed below, this parameteris used by the controller 132 to automatically control swing phase kneeresistances for substantially all patients at substantially all speeds.

[0135] In one preferred embodiment, the speed control parameter is theamount of time the prosthetic foot remains in contact with the ground,or foot contact time. In another preferred embodiment, the speed controlparameter is the maximum flexion velocity that occurs betweensubstantially maximum or full extension and about thirty degrees flexionas the leg prosthesis flexes from State 3 to State 4. In other preferredembodiments, other suitable speed control parameters may be used, asneeded or desired, giving due consideration to the goals of adaptivelycontrolling knee resistances at various speeds, and/or of achieving oneor more of the benefits and advantages as taught or suggested herein.

[0136] The foot contact time is preferably measured or computed during aparticular time period. Preferably, the foot contact time is measuredduring one stance phase. Alternatively, the foot contact time may bemeasured or computed over one or more gait cycles. The foot contact timeis preferably computed based on signals from the axial force sensors140. A nonzero axial force measurement indicates that the prostheticfoot is in contact with the ground or other supporting surface.

[0137] Referring to FIG. 7, typically, as walking speed increases, footcontact time decreases. In FIG. 7, foot contact time for one subject isplotted against forward walking and running speed, showing decreasingtimes with increasing speeds. The x-axis 192 represents the forwardspeed in cm/sec and the y-axis 194 represents the foot contact timeduring one stance phase in seconds.

[0138] In FIG. 7, triangles show contact times for a non-amputee movingat several distinct steady state speeds from slow walking at 0.85meters/sec to moderate running at 1.74 meters/sec. As seen in FIG. 7,contact time generally decreases with increasing speed. A least-squaresregression line is fitted to the data with a slope of about −0.32sec²/meter. Similar regressions were observed for both amputees andnon-amputees. Data were collected using a four-camera bilateralkinematic data-acquisition system based on Selspot II cameras fromSelective Electronics Co., Partille, Sweden (Unpublished data fromMassachusetts General Hospital Gait Laboratory, Boston, Mass.).

[0139] In accordance with one preferred embodiment, the controller 132through an iterative process determines how swing phase knee resistancesor damping are modulated with foot contact time or locomotory speed. Thefull biological range of foot contact time is stored in the memory 150of the knee's processor 132. Typically, a person of short stature has,on average, smaller foot contact times compared with a person of tallstature. The full biological range stored in the memory 150 preferablyincludes both these extremes.

[0140] In one preferred embodiment, the memory 150 stores a foot contacttime of zero to about two seconds which is generally more thansufficient to cover the full biological range of foot contact times. Inother preferred embodiments, the memory may store a smaller or largerrange of foot contacts times with efficacy, as required or desired,giving due consideration to the goals of covering the full biologicalrange of foot contact times, and/or of achieving one or more of thebenefits and advantages as taught or suggested herein.

[0141] Preferably, the foot contact time range is partitioned into timeslots or partitions within the microprocessor memory 150. When anamputee moves from a slow to a fast walk different time slots orlocomotory velocity ranges are sampled. Since the entire biologicalrange is partitioned, each amputee, independent of height, weight orbody size, samples multiple time slots when moving from a slow to a fastwalk or run.

[0142] In one preferred embodiment, the partition size is about 100milliseconds (msecs), thus giving a total of twenty time slots over atwo-second foot contact time range or interval. Any one amputee wouldtypically sample not all but a fraction of the twenty time slots whenmoving from a slow to a fast locomotory pace. In other preferredembodiments, the partition size can be alternately selected withefficacy, as required or desired, giving due consideration to the goalsof achieving one or more of the benefits and advantages as taught orsuggested herein.

[0143] The control scheme of one preferred embodiment preferablymodulates knee damping profiles within each time slot. In State 4,damping values are modulated within each time slot to control peakflexion angle, and in State 5, the impact force of the extending legagainst the artificial knee cap is controlled. Based on sensory dataprovided to the controller 132 (as discussed above), the controller 132sends appropriate command signals or instructions to the knee brake ordamper 130.

[0144] State 4 (Swing Flexion):

[0145] When an amputee first walks or takes a first step utilizing theprosthetic knee system 110 as controlled by the preferred controlschemes of the invention, preferably, the microprocessor or controller132 initially sets or adjusts State 4 damping or resistance to kneerotation to its lowest value within each time slot. Hence, when anamputee takes a first step, State 4 knee damping torque is minimized,and the knee swings freely throughout early swing phase.

[0146] Preferably, this minimum value of the knee damping torque isabout 0.4 N-m and is largely determined by the particular knee brakeutilized. Alternatively, other minimum damping torque values and/orvariable torques may be utilized with efficacy, as needed or desired,giving due consideration to the goals of achieving one or more of thebenefits and advantages as taught or suggested herein.

[0147] For subsequent steps or gait cycles, after the first step, thecontroller 132 preferably increases brake damping by sending appropriatecommand signals or instructions to the knee brake 130 whenever the kneeflexes to an angle greater than a fixed or predetermined target angle.For walking non-amputees, peak flexion angle during early swingtypically does not exceed about 80° (see FIG. 3).

[0148] Hence, in accordance with one preferred embodiment, to achieve agait cycle that is substantially natural or biological, the target angleis set equal to about 80° to control the State 4 peak flexion angle ofthe prosthetic knee system 110. In other preferred embodiments, and/orother activity levels or external conditions, the State 4 target anglecan be alternately selected, as needed or desired, giving dueconsideration to the goals of providing a substantially life-likeresponse, and/or of achieving one or more of the benefits and advantagesas taught or suggested herein.

[0149] The microprocessor 132 preferably increases damping by an amountthat is proportional to the error or difference between the actualflexion angle, measured by the angle sensor 134, and the target angle.Increased damping lowers the peak flexion angle for future gait cycles,but preferably only in those time slots or locomotory speeds which theamputee has sampled.

[0150] In State 4, when the peak flexion angle falls below the targetangle the microprocessor 132 decreases the damping torque by sendingappropriate command signals or instructions to the knee brake 130. Thisensures that damping levels are not unnecessarily high.

[0151] Preferably, the damping torque is decreased when the peak flexionangle falls below the target angle for N consecutive locomotory steps,cycles or strides. One preferred value for N is about twenty locomotoryor gait cycles, though other values may be efficaciously utilized. Thebrake damping is preferably decreased by an amount proportional to theerror or difference between the actual flexion angle, measured by theangle sensor 134, and the target angle. Within any particular time slotor bin, decreased damping raises the peak flexion angle for future gaitcycles.

[0152] Typically, at faster walking speeds, a greater damping level isrequired to keep the peak flexion angle in State 4 below the targetangle threshold. Hence, to increase State 4 adaptation speed, in onepreferred embodiment, the control scheme is designed such that dampinglevels at faster walking speeds or time slots are at least as high asdamping levels at slower speeds or time slots.

[0153] Moreover, preferably, the State 4 damping levels applied in eachtime slot over one gait or locomotory cycle are constant, though theymay be variable or angle dependent. Additionally, the modulation ofState 4 damping levels in one or more time slots may involve changingthe damping over a fixed or predetermined knee angle range or changingthe angle range over which damping is applied or a combination thereof.

[0154] As the amputee continues to use the prosthetic knee system 110and samples a diverse range of walking, running or other locomotoryspeeds, State 4 knee damping gradually converges within each time slotuntil peak knee flexion always falls below, or close to, the targetangle for substantially all walking, running or other locomotory speeds.The optimized damping torque values or profiles for each time slot orlocomotory speed are stored in the microprocessor memory 150. Hence,once the iterative adaptive control scheme has been implemented, theamputee can rapidly accelerate from a slow to a fast walk all the whilesampling different time slots, and therefore, different damping levelswithin State 4.

[0155] State 5 (Swing Extension):

[0156] A similar scheme or strategy is used to control the force ofimpact when the swinging prosthesis strikes the artificial knee cap. Asnoted above, this artificial knee cap serves as an extension stop.

[0157] When an amputee first walks or takes a first step utilizing theprosthetic knee system 110 as controlled by the preferred controlschemes of the invention, preferably, the microprocessor or controller132 initially sets or adjusts State 5 damping to its lowest value withineach time slot. Hence, when an amputee takes a first step, State 5 kneedamping torque is minimized, and the knee extends from the peak flexionangle in State 4 to the maximum extension angle (about 180°) in State 5.Contact with the artificial knee cap prevents further extension.

[0158] Preferably, this minimum value of the knee damping torque isabout 0.4 N-m and is largely determined by the particular knee brakeutilized. Alternatively, other minimum damping torque values and/orvariable torques may be utilized with efficacy, as needed or desired,giving due consideration to the goals of achieving one or more of thebenefits and advantages as taught or suggested herein.

[0159] For subsequent steps or gait cycles, after the first step, thecontroller 132 computes an average impact force of the swinging legagainst the artificial kneecap, within each bin or time slot, with thedamping minimized. From the smallest of the M time slots or bins to thelargest, if two consecutive bins are not directly adjacent then a linearextrapolation is performed to estimate the average impact forces forintermediate bins. For example, if averages are computed for bins “ten”and “twelve”, but not for bin “eleven”, then a linear extrapolation fromthe impact force corresponding to bin “ten” to the impact forcecorresponding to bin “twelve” is computed. This linear function is thenemployed to estimate an impact force for bin “eleven”. The M bin regionpreferably comprises between about three to five bins or time slots,though fewer or more may be efficaciously used, as needed or desired.

[0160] After M average impact forces are computed and linearextrapolations are formulated from the minimum to the maximum bins, kneedamping values are selected using a clinically determined relationshiprelating impact force to optimal extension damping. Hence, the amputeefeels damping tending to decelerate the extending leg but only forwalking speeds corresponding to the M bin region. For bins above themaximum and below the minimum, the default minimum damping is used untiladditional data are collected and average impact forces are computed.For bins above and below the original M bin region, linearextrapolations are preformed to estimate average impact forces forintermediate bins. For example, if the maximum of the original M bins isequal to “fourteen”, and an average impact force is computed for bin“seventeen”, then impact forces are estimated for bins “fifteen” and“sixteen” using a linear finction from the average impact forcecorresponding to bin “fourteen” and the average force corresponding tobin “seventeen”. Once average impact forces are computed for bins aboveand below the region of the original M bins, knee damping values areselected using a clinically determined relationship relating impactforce to optimal extension damping.

[0161] The clinically determined relationship relating impact force tooptimal extension damping is preferably derived or determined by aclinical investigation utilizing patients moving at different walking,running and or other locomotory speeds. Preferably, the clinicallydetermined relationship relating impact force to optimal extensiondamping is derived or determined by a clinical investigation utilizingpatients having different body sizes (weights). This clinicallydetermined relationship is preferably stored in the system memory 150.

[0162] For each time slot or bin, once an optimal extension dampingvalue has been selected, the microprocessor 132 once again computes anaverage impact force, and this new average force is then used as atarget. If a system disturbance occurs that significantly alters themagnitude of impact force within a particular bin, then extensiondamping is modulated until the impact force is once again equal to, orin the proximity of, the target impact force. For example, within aparticular bin, if the average impact force after the damping is turnedon is 100 Newtons, and a disturbance causes the swinging leg to impactthe artificial kneecap with a force of 150 Newtons, then extensiondamping is increased for that bin until the impact force is once againequal to, or approximately close to, the original 100 Newtons. With thisadaptive routine, the amputee can change from a lightweight shoe to aheavy shoe and still walk comfortably without having to return to theirprosthetist for re-programming.

[0163] The average impact force of the swinging leg against theartificial kneecap is preferably computed by the controller 132 usingsignals or data provided by sensors local to the prosthesis. The impactforce sensors preferably comprise the sensors 140 and include one ormore strain gauges mounted on or mechanically connected to the frame141, as discussed above. Based on the computed or determined impactforce, the controller 132 provides appropriate command signals orinstructions to the knee brake 130 to control the knee damping.

[0164] State 5 damping, in each time slot or locomotory speed, can bemodulated by several methods in the preferred embodiments of the controlscheme of the invention. For example, the modulation of State 5 dampinglevels in one or more time slots may involve changing the damping over afixed or predetermined knee angle range or changing the angle range overwhich damping is applied or a combination thereof. Additionally, State 5damping levels applied in one or more time slots over one gait orlocomotory cycle may be constant, variable and/or angle dependent.

[0165] In accordance with one preferred embodiment, the control schememodulates the knee damping in State 5 over or within a fixed orpredetermined angle range. For example, knee damping torque is increasedor decreased within a particular extension angle range such as in therange from about 130° to about 180° to increase or decrease the dampingwithin that particular time slot.

[0166] In accordance with another preferred embodiment, the controlscheme keeps the State 5 knee damping levels substantially constant andinstead modulates the angle range over which knee damping is applied.For example, the knee damping is constant and maximized, and thisdamping is applied over an extension angle range of about 170° to about180°. To increase State 5 damping, the starting extension angle for theinitiation of knee damping could be changed from about 170° to about160° to increase the State 5 damping for that particular time slot orlocomotory speed.

[0167] Typically, at faster walking speeds, a greater damping level isrequired to keep the impact force against the artificial kneecap at anacceptable range. Hence, to increase State 5 adaptation speed, in onepreferred embodiment, the control scheme is designed such that dampinglevels at faster walking speeds or time slots are at least as high asdamping levels at slower speeds or time slots.

[0168] As the amputee continues to use the prosthetic knee system 110and samples a diverse range of walking and running speeds, State 5 kneedamping gradually converges within each time slot until the impactforces of the swinging leg against the artificial kneecap are held at anacceptable level for substantially all walking, running or otherlocomotory speeds. The optimized damping torque values or profiles foreach time slot or locomotory speed are stored in the microprocessormemory 150. Hence, once the iterative adaptive control scheme has beenimplemented, the amputee can rapidly accelerate from a slow to a fastwalk all the while sampling different time slots, and therefore,different damping levels within State 5.

[0169] As the patient further continues to use the prosthetic kneesystem 110, further automated refinements and fine-tuning can be made bythe system 110, as necessary. The prosthesis of the preferredembodiments is a self-teaching and/or self-learning system that isguided by clinical (prosthetic) and biomechanical knowledge. Forexample, biomechanical knowledge (stored in the system memory) includesinformation related to the mechanics of typical human walking/running,as discussed above in reference to FIG. 1.

[0170] Advantageously, no patient-specific is needed by the controlscheme and prosthetic knee system of the preferred embodiments, andhence no pre-programming by a prosthetist or amputee is needed toaccommodate different locomotory speeds and different patients. Thesystem is able to adapt to various types of disturbances once thepatient leaves the prosthetist's facility because it is patient-adaptiveand speed-adaptive. Desirably, this also saves on time and cost, andsubstantially eliminates or mitigates inconvenience, discomfort andfatigue for the patient during an otherwise lengthy adjustment or trialperiod.

[0171] The control scheme and prosthesis of the preferred embodimentsallow the patient to perform a wide variety of activities. These includenormal walking or running on a level or inclined surface, sitting down,ascending or descending steps or other situations, for example, when auser lifts a suitcase.

[0172] Magnetorheological Knee Brake

[0173] Preferred embodiments of a magnetorheological knee brake oractuator in accordance with the present invention are described incopending U.S. application Ser. No. 09/767,367, filed Jan. 22, 2001,entitled “ELECTRONICALLY CONTROLLED PROSTHETIC KNEE,” the entiredisclosure of which is hereby incorporated by reference herein. Forpurposes of clarity and brevity of disclosure, only a brief descriptionof this magnetorheological knee brake or actuator is set forth below.

[0174]FIG. 8 is a simplified schematic of a rotary prosthetic knee brakeor magnetorheological (MR) braking system 210 in accordance with onepreferred embodiment of the present invention. The knee actuator 210includes a substantially central core 212 substantially circumscribed orenveloped by an electromagnet or magnetic coil 214 and in mechanicalcommunication with a pair of side plates or disks 216, 218. By passing avariable, controlled current through the electromagnet 214, a variablemagnetic field is created. Preferably, the core 212 and side plates 216,218 are fabricated from a ferrous, magnetizable or magnetic material andthe like. More preferably, the core 212 and side plates 216, 218 arefabricated from a magnetically soft material of high flux saturationdensity and high magnetic permeability.

[0175] The prosthetic knee brake or actuator 210 further includes aplurality of inner blades or plates 220 in mechanical communication withan inner spline 222. The inner spline 222 generally circumscribes orenvelops the electromagnet 214 and is coupled or mechanically connectedto the side plates 216, 218. The blades 220 are preferablyconcentrically arranged about the brake axis of rotation 224. The innerspline 222 is preferably rotatable about the knee joint axis of rotation224, and hence so are the blades or rotors 220 and the core side plates216, 218. Rotation of the inner spline 222 corresponds to rotation ormovement of the lower (below the knee) part of the leg.

[0176] The prosthetic knee brake or actuator 210 also comprises aplurality of outer blades or plates 230 in mechanical communication withan outer spline 232. The outer spline 232 generally circumscribes orenvelops the inner spline 222. The blades 230 are preferablyconcentrically arranged about the brake axis of rotation 224. The outerspline 232 is preferably rotatable about the knee joint axis of rotation224, and hence so are the blades or stators 230. Rotation of the outerspline 232 corresponds to rotation or movement of the upper (above theknee) part of the leg. Preferably, the outer spline or housing 232comprises means to facilitate connection of the prosthetic knee joint210 to a suitable stump socket or the like. The outer spline 232, andhence the stators 230, are preferably substantially irrotationallycoupled to or nonrotatable with respect to the stump socket or residuallimb.

[0177] The plurality of rotors 220 and stators 230 are interspersed inan alternating fashion and the gaps between adjacent blades 220 and 230comprise a magnetorheological (MR) fluid 234, which thereby resides inthe cavity or passage formed between the inner spline 222 and the outerspline 232. In one preferred embodiment, the MR fluid 234 in the gaps ormicrogaps between adjacent rotors 220 and stators 230 is in the form ofthin lubricating films between adjacent rotors 220 and stators 230.Shearing of MR fluid present between the side plates 216, 218 andadjacent stators 230 can also contribute to the knee damping.

[0178] During knee joint rotation, the MR fluid in the plurality of gapsbetween the rotors 220 and stators 230 is sheared to generate a dampingtorque to control the limb rotation. The blades or disks 220 and 230 arepreferably formed of a ferrous, magnetizable or magnetic material andthe like. More preferably, the blades or disks 220 and 230 are formed ofa material of as high magnetic permeability and magnetic softness as ismechanically practical.

[0179] The knee joint actuator 210 further includes a pair of ballbearings 226, 228 coupled or connected to the respective side plates216, 218. The ball bearings 226, 228 are further coupled or connected torespective side walls or mounting forks 236, 238. Thus, a rotarycoupling is created between the inner spline 222 and the mounting forks236, 238. The mounting forks 236, 238 in combination with the outerspline 232 form one main outer shell of the knee actuator 210.Preferably, the side walls or mounting forks 236, 238 comprise means tofacilitate connection of the prosthetic knee actuator 210 to a suitablepylon, shank portion or the like.

[0180] Preferably, the central core 212 and the electromagnet 214 alsorotate along with the rotation of the inner spline 222, the rotors 220,the core side plates 216, 218 and the mounting forks 236, 238. Thestators 230 rotate together with the rotation of the outer spline 232.

[0181] The rotors 220 are rotationally fixed relative to the innerspline 222 and the stators 230 are rotationally fixed relative to theouter spline 232. During various stages of locomotion or knee rotation,and about the knee axis of rotation 224, the rotors 220 may rotate whilethe stators 230 are rotationally substantially stationary, or thestators 230 may rotate while the rotors 220 are rotationallysubstantially stationary, or both the rotors 220 and the stators 230 mayrotate or be substantially rotationally stationary. The terms “rotor”and “stator” are used to distinguish the inner blades 220 and the outerblades 230, though both rotors 220 and stators 230 can rotate, and teachthat relative rotational motion is created between the rotors 220 andthe stators 230 (with MR fluid being sheared in the gaps betweenadjacent rotors 220 and stators 230). If desired, the blades 220 can bereferred to as the “inner rotors” and the blades 230 as the “outerrotors.”

[0182] Actuation of the magnet 214 causes a magnetic field, circuit orpath 240 to be generated or created within the knee actuator 210. In onepreferred embodiment, the magnetic field 240 passes through the centralcore 212, radially outwards through the side plate 218, laterallythrough the interspersed set of rotors 220 and stators 230 and themagnetorheological fluid 234, and radially inwards through the sideplate 216. The portion of the magnetic field 240 passing through thecore 212 and side plates 216, 218 generally defines the magnetic returnpath while the active or functional magnetic field is generally definedby the magnetic path through the rotors 220, stators 230 and MR fluid234.

[0183] The magnetorheological (NMR) fluid 234 undergoes a rheology orviscosity change which is dependent on the magnitude of the appliedmagnetic field. In turn, this variation in fluid viscosity determinesthe magnitude of the shearing force/stress, torque or torsionalresistance generated, and hence the level of damping provided by theprosthetic knee brake 210. Thus, by controlling the magnitude of thismagnetic field, the rotary motion of the artificial limb is controlled,for example, to control the flexion and extension during swing andstance phases to provide a more natural and safe ambulation for theamputee.

[0184] In one preferred embodiment, the rotors 220 and/or stators 230are displaceable in the lateral direction 242, and hence under theinfluence of a magnetic field can rub against adjacent rotors 220 and/orstators 230 with a variable force determined by the strength of themagnetic field to create a “hybrid” magnetorheological and frictionaldamping brake. In another preferred embodiment, the rotors 220 andstators 230 are laterally fixed in position relative to the splines 222and 232, and hence the braking effect is substantially purelymagnetorheological or viscous. Alternatively, some of the rotors 220and/or stators 230 may be laterally fixed while others may be laterallydisplaceable, as required or desired, giving due consideration to thegoals of providing a substantially natural feeling and/or safeprosthetic device, and/or of achieving one or more of the benefits andadvantages as taught or suggested herein. In one embodiment, the sideplates 216, 218 are laterally displaceable and contribute to thefrictional damping due to frictional contact with adjacent stators 230.

[0185] Advantageously, by operating in the shear mode, there is no ornegligible pressure build-up within the MR actuated prosthetic knee ofthe present invention. This substantially eliminates or reduces thechances of fluid leakage and failure of the knee, and hence desirablyadds to the safety of the device.

[0186] Also advantageously, the multiple shearing surfaces or fluxinterfaces, provided by the preferred embodiments of the presentinvention, behave like a torque multiplier and allow the viscous torquelevel to be stepped up to a desired maximum value without the use of anadditional transmission or other auxiliary component. For example, iftwo flux interfaces can provide a maximum viscous torque of about 1 N/m,then forty flux interfaces will be able to provide a viscous dampingtorque of about 40 N/m. In contrast, if a 40:1 step-up transmission isused to increase the viscous torque, disadvantageously, not only is thesystem reflected inertia magnified by a factor of about 1600, but thesystem weight, size and complexity are undesirably increased.

[0187] The multiple shearing surfaces or interfaces of the prostheticknee actuator of the preferred embodiments also advantageously allow fora wide dynamic torque range to be achieved which permits safe and/ormore natural ambulation for the patient. Desirably, the MR actuatedprosthetic knee of the preferred embodiments provides a rapid andprecise response. Again, this permits the patient to move in a safeand/or more natural manner.

[0188]FIGS. 9 and 10 show a magnetorheological rotary prosthetic kneeactuator, brake or damper 210 having features and advantages inaccordance with one preferred embodiment of the present invention. Theprosthetic knee actuator 210 generates controllable dissipative forcespreferably substantially along or about the knee axis of rotation 224.The knee actuator embodiment of FIGS. 9 and 10 is generally similar inoperation and structure to the knee actuator embodiment of FIG. 8, andhence for purposes of clarity and brevity of disclosure only a briefdescription of the embodiment of FIGS. 9 and 10 is set forth below.

[0189] The electronically controlled knee actuator 210 generallycomprises a generally central core 212 in mechanical communication witha pair of rotatable side plates 216, 218, an electromagnet 214, aplurality of blades or rotors 220 in mechanical communication with arotatable inner spline 222, a plurality of blades or stators 230 inmechanical communication with a rotatable outer spline 232, a pair ofball bearings 226, 228 for transferring rotary motion to a pair of outerside walls or forks 236, 238. The rotation is substantially about theknee axis of rotation 224.

[0190] The plurality of rotors 220 and stators 230 are preferablyinterspersed in an alternating fashion and the gaps or microgaps betweenadjacent blades 220 and 230 comprise thin lubricating films of amagnetorheological (MR) fluid, which thereby resides in the cavity orpassage formed between the inner spline 222 and the outer spline 232.This preferred embodiment provides a controllable and reliableartificial knee joint, which advantageously has a wide dynamic torquerange, by shearing the MR fluid in the multiple gaps or flux interfacesbetween adjacent rotors 220 and stators 230.

[0191] Preferably, end-threaded rods 248 and nuts 250 are used to secureselected components of the prosthetic knee 210, thereby allowing astraightforward assembly and disassembly procedure with a minimum offasteners. Alternatively, or in addition, various other types offasteners, for example, screws, pins, locks, clamps and the like, may beefficaciously utilized, as required or desired, giving due considerationto the goals of providing secure attachment, and/or of achieving one ormore of the benefits and advantages as taught or suggested herein.

[0192] In one preferred embodiment, the prosthetic knee brake 210further comprises a flexion stop system or assembly. The flexion stopsystem controls the maximum allowable flexion angle by physicallylimiting the rotation between the outer side forks 236, 238 and theouter spline 232, and hence the rotation of the knee joint.

[0193] In one preferred embodiment, the prosthetic knee brake 210further comprises an extension stop system or assembly. The extensionstop system controls the maximum allowable extension angle by physicallylimiting the rotation between the outer side forks 236, 238 and theouter spline 232, and hence the rotation of the knee joint.

[0194] In one preferred embodiment, the prosthetic knee brake 210further comprises an extension assist to help straighten the leg byurging or biasing the leg to extension by applying a controlled torqueor force. Any one of a number of devices, such as a spring-loadedextension assist, as known in the art may be used in conjunction withthe present invention.

[0195] In one preferred embodiment, the prosthetic knee brake 210comprises forty rotors 220 and forty one stators 230 interspersed in analternating fashion. This results in forty flux interfaces or fluid gapsin which the magnetorheological (MR) fluid resides. In another preferredembodiment, the number of rotors 220 is about ten to one hundred, thenumber of stators 230 is about eleven to one hundred one so that thenumber of MR fluid to rotor interfaces which produce braking in thepresence of a magnetic field is twice the number of rotors. In yetanother preferred embodiment, the number of rotors 220 is in the rangeof one to one hundred. In a further preferred embodiment, the number ofstators 230 is in the range of one to one hundred. In other preferredembodiments, the number of rotors 220, stators 230 and/or fluxinterfaces may be alternately selected with efficacy, as needed ordesired, giving due consideration to the goals of providing a widedynamic torque range, and/or of achieving one or more of the benefitsand advantages as taught or suggested herein.

[0196] Advantageously, the induced yield stress or viscous torque isproportional to the overlap area between a rotor-stator pair multipliedby twice the number of rotors (the number of MR fluid to rotorinterfaces which produce braking torque in the presence of a magneticfield). This desirably allows the viscous torque or yield stress to beincreased or decreased by selecting or predetermining the number ofrotors 220 and/or stators 230 and/or the overlap or mating surface areabetween adjacent rotors 220 and/or stators 230. Another advantage isthat this permits control over the overall size, that is radial size andlateral size, of the MR actuated prosthetic brake 210. For example, theoverall knee configuration may be made radially larger and laterallyslimmer while providing the same viscous torque range by appropriateselection of the number of flux interfaces and the overlap area of theshearing surfaces.

[0197] It is desirable to minimize the MR fluid gap between adjacentrotors 220 and stators 230 since the power needed to saturate the totalMR fluid gap is a strong function of the gap size. Thus, advantageously,a smaller gap size renders the MR actuated brake 210 more efficient andreduces power consumption.

[0198] Preferably, the MR fluid gap size is also selected so that in theabsence of an applied magnetic field only a viscous damping force ortorque component is present from the shearing of MR fluid betweenadjacent rotor and stator surfaces. That is, there is no frictionaltorque component between the rotors 220 and stators 230 under zero-field conditions.

[0199] Accordingly, in one preferred embodiment, the power required tosaturate the MR fluid is lowered and the dynamic range of the knee isenhanced by minimizing the MR fluid gap size. In this embodiment, thegap is not reduced so much that, under zero-field conditions, a normalforce acts between adjacent rotor and stator surfaces, causingfrictional rubbing. The absence of friction between rotors and statorsenables the knee joint to swing freely, thereby providing a widerdynamic range. As a note, the viscous damping at zero-field does notincrease dramatically with decreasing fluid gap because the MR fluidexhibits a property known as shear rate thinning in which fluidviscosity decreases with increasing shear rate.

[0200] In one preferred embodiment, the MR fluid gap size or widthbetween adjacent rotors 220 and stators 230 is about 40 microns (μm) orless. In another preferred embodiment, the MR fluid gap size or widthbetween adjacent rotors 220 and stators 230 is in the range from about10 μm to about 100 μm. In other preferred embodiments, the MR fluid gapsize can be alternately dimensioned and/or configured with efficacy, asrequired or desired, giving due consideration to the goals of providingan energy efficient prosthetic knee actuator 210 having a wide dynamictorque range, and/or of achieving one or more of the benefits andadvantages as taught or suggested herein.

[0201] The electronically controlled magnetorheologically actuatedprosthetic knee brake of the preferred embodiments provides high-speedinstantly responsive control of knee movement, yet is robust andaffordable for the amputee. The preferred embodiments advantageouslyprovide improved stability, gait balance and energy efficiency foramputees and simulate and/or closely recreate the dynamics of a naturalknee joint.

[0202] During operation, the electromagnet or magnetic coil 214 isactuated, as needed, by a selected or predetermined electrical signal,voltage or current to generate an active variable magnetic field passingsubstantially perpendicularly to the plurality of rotor and statorsurfaces and through the MR fluid or film between adjacent rotors 220and stators 230 to generate a variable damping torque (or rotaryresistive force) which precisely and accurately controls the rotarymotion of the prosthetic knee 210. As discussed above, in accordancewith one preferred embodiment, the torque comprises a frictional dampingcomponent.

[0203] Desirably, the MR actuated prosthetic knee 210 of the preferredembodiments provides a rapid and precise response. The materials in MRparticles respond to the applied magnetic field within milliseconds,thereby allowing for real-time control of the fluid rheology and theknee motion. This facilitates in permitting the patient to move in asafe and/or more natural manner.

[0204] Advantageously, the viscous damping torque is generated byshearing of the MR fluid. Hence, there is no or negligible pressurebuild-up or change within the MR actuated prosthetic knee 210 of thepresent invention. This substantially eliminates or reduces the chancesof fluid leakage and failure of the knee, and hence desirably adds tothe safety. Moreover, costly and/or relatively complex components suchas pressure bearings and the like need not be utilized to provide areliable seal.

[0205] Another advantage is that the plurality of shearing surfaces orflux interfaces between adjacent rotors 220 and stators 230 behave likea torque multiplier and allow the viscous torque level (and/orfrictional torque) to be stepped up to a desired maximum value withoutthe use of an additional transmission or other auxiliary component.Moreover, the flexibility in selecting the overlap surface area betweenadjacent rotors 220 and stators 230 can also increase or decrease themaximum attainable viscous torque (and/or frictional torque). Thus,desirably a wide dynamic torque or torsional resistance range can beprovided, as needed or desired, which adds to the versatility of theinvention without adding substantially to system size, weight andcomplexity.

[0206] In one preferred embodiment, the prosthetic knee actuator of thepreferred embodiments provides a maximum dynamic torque of about 40Newton-meters (N-m). In another preferred embodiment, the prostheticknee actuator of the preferred embodiments provides a dynamic torque inthe range from about 0.5 N-m to about 40 N-m. In yet another preferredembodiment, the prosthetic knee actuator of the preferred embodimentsprovides a dynamic torque in the range from about 1 N-m to about 50 N-m.In other preferred embodiments, the prosthetic knee actuator can provideother dynamic torque ranges with efficacy, as needed or desired, givingdue consideration to the goals of achieving one or more of the benefitsand advantages as taught or suggested herein.

[0207] Also advantageously, the optimized thinness of the MR fluid gapbetween adjacent rotors 220 and stators 230 provides a higher maximumtorque, a wider dynamic torque range and requires less energyconsumption, preferably about 10 Watts or less. This adds to theefficiency and practicality of the MR actuated prosthetic brake 210 ofthe preferred embodiments and also saves on cost since a lower wattageand/or less complex power source can be used.

[0208] While the components and techniques of the present invention havebeen described with a certain degree of particularity, it is manifestthat many changes may be made in the specific designs, constructions andmethodology hereinabove described without departing from the spirit andscope of this disclosure. It should be understood that the invention isnot limited to the embodiments set forth herein for purposes ofexemplification, but is to be defined only by a fair reading of theappended claims, including the full range of equivalency to which eachelement thereof is entitled.

What is claimed is:
 1. A method of adaptively controlling the stancephase damping of a prosthetic knee worn by a patient, comprising thesteps of: providing a memory in said prosthetic knee, said memory havingstored therein correlations between sensory data and stance phasedamping established in clinical investigations of amputees of varyingbody size; measuring instantaneous sensory information using sensorslocal to said prosthetic knee as said patient stands, walks or runs; andusing the instantaneous sensory information in conjunction with saidcorrelations to automatically adjust stance phase damping suitable forsaid patient without requiring patient specific information to bepre-programmed in said prosthetic knee.
 2. The method of claim 1,wherein said correlations characterize knee behavior during stancephase.
 3. The method of claim 1, wherein said memory has further storedtherein biomechanical information.
 4. The method of claim 1, whereinsaid step of measuring instantaneous sensory information comprises thestep of measuring axial force.
 5. The method of claim 1, wherein saidstep of measuring instantaneous sensory information comprises the stepof measuring moment.
 6. The method of claim 1, wherein said step ofmeasuring instantaneous sensory information comprises the step ofmeasuring knee angle.
 7. A method of adaptively controlling the swingphase damping torque of a prosthetic knee worn by a patient as thepatient travels at various locomotory speeds, ground contact time of aprosthetic foot connected to said prosthetic knee by a prosthetic legbeing indicative of the locomotory speed of said patient, said methodcomprising the steps of: continuously measuring the contact time overperiods of one gait cycle as said patient ambulates at variouslocomotory speeds; storing the contact time within a memory of saidprosthetic knee in time slots corresponding to the locomotory speed ofsaid patient; iteratively modulating the swing phase damping for kneeflexion to achieve a target peak flexion angle range until the dampingconverges within each time slot; iteratively modulating the swing phasedamping for knee extension to control the impact force of the extendingprosthetic leg against an artificial knee cap of said prosthetic kneeuntil the extension damping converges within each time slot; and usingthe converged damping values to automatically control swing phasedamping at all locomotory speeds.
 8. The method of claim 7, furthercomprising the step of measuring the knee angle.
 9. The method of claim7, further comprising the step of measuring said impact force usingsensors.
 10. The method of claim 7, wherein said memory has storedtherein a clinically determined relationship relating said impact forceto optimal extension damping.
 11. The method of claim 7, furthercomprising the step of modulating knee extension damping within apredetermined knee angle range.
 12. The method of claim 7, furthercomprising the step of modulating the knee angle range over which kneeextension damping is applied.
 13. An adaptive prosthetic knee forcontrolling the knee damping torque during stance phase of an amputee,comprising: a controllable knee actuator for providing a variabledamping torque in response to command signals; sensors for measuring theforce and moment applied to said prosthetic knee as said amputee movesover a supporting surface; a controller having a memory and adapted tocommunicate command signals to said knee actuator and receive inputsignals from said sensors, said memory having stored thereinrelationships between sensory data and stance phase damping establishedin prior clinical investigations of patients of varying body size;whereby, said controller utilizes sensory data from said sensors inconjunction with said relationships to adaptively and automaticallycontrol the damping torque provided by said knee actuator during stancephase independent of any prior knowledge of the size of the amputee. 14.The prosthetic knee of claim 13, wherein said knee actuator comprises amagnetorheological brake.
 15. The prosthetic knee of claim 13, whereinsaid knee actuator comprises a viscous torque brake.
 16. The prostheticknee of claim 13, wherein said knee actuator comprises a pneumaticbrake.
 17. The prosthetic knee of claim 13, wherein said knee actuatorcomprises a dry friction brake.
 18. The prosthetic knee of claim 13,wherein said sensors comprise a plurality of strain gauges.
 19. Theprosthetic knee of claim 13, further comprising an angle sensingpotentiometer to measure the knee angle.
 20. The prosthetic knee ofclaim 13, wherein said memory has further stored therein biomechanicalinformation to guide the modulation of damping.
 21. The prosthetic kneeof claim 13, further comprising a safety system to put the prostheticknee in a default safety mode when a system error is detected by saidcontroller.
 22. The prosthetic knee of claim 21, further comprising anaudible warning transducer to warn the amputee prior to the activationof the default safety mode.
 23. The prosthetic knee of claim 21, furthercomprising a vibration transducer to warn the amputee prior to theactivation of the default safety mode.
 24. The prosthetic knee of claim13, further comprising a frame housing said knee actuator and saidcontroller.
 25. A prosthetic assembly, comprising: the prosthetic kneeas recited in claim 24; a stump socket in mechanical communication withsaid prosthetic knee and adapted to receive the residual limb of anamputee; a prosthetic shank portion in mechanical communication withsaid prosthetic knee; and a prosthetic foot in mechanical communicationwith said prosthetic shank portion.